B A S I C     B L O C K TM  5-3805-258-24-1 T E S T I N G      A N D      A D J U S T I NG BASIC BLOCK PISTON RING GROOVE GAUGE Make reference to GUIDELINE FOR REUSA- BLE   PARTS:   PISTONS   AND   CYLINDER LINERS, Form No. SEBF8001. The   5P4812   KEYSTONE   PISTON   RING GAUGE  GROUP  is  necessary  for  measuring  these grooves. Put the pin end of gauge “2” in the groove at four places around the circumference. Do this to both grooves. The flat edge of the gauge must be between the grooves. If there is clearance between the flat edge of the gauge and the piston at all test locations, for both grooves, the piston is reusable. If the flat edge is in contact with the piston, at any of the test locations, the piston is not reusable. Install a new piston. 5 P 4 8 1 2      K E Y S T O N E      P I S T ON R I N G     G R O O V E     G A U G E     G R O U P CONNECTING  RODS  AND  PISTONS Use the 7S9470 Piston Ring Expander to remove or install piston rings. Use the 5P3525 Piston Ring Compressor to install pistons  into  cylinder  block. Tighten the connecting rod nuts in the step se- quence  that  follows: 1. Put engine oil on threads. 2. Tighten both nuts to 40 ± 4  N-m (30 ± 3 lb. ft.). 3. Put a mark on each nut and cap. 4. Tighten each nut 90° from the mark. The connecting rod bearings must fit tightly in the bore in the rod. If bearing joints or backs are worn (fretted), check for bore size as this is an indication of wear  because  of  looseness. CONNECTING ROD AND MAIN BEARINGS Bearings are available with 0.25 mm (.010 in.), 0.51 mm (.020 in.) and 0.76 mm (.030 in.) smaller inside diameter than the original size bearings. These bearings   are   for   crankshafts   that   have   been “ground” (made smaller) than the original size. CYLINDER LINER PROJECTION Tools    Needed: 1P5510    Liner    Projection     Tool    Group. 1P2403    Dial   Indicator. 1P5512    Contact    Point    22.4    mm   (.88   in.)    long. 1P2402    Gauge    Body. 1P5507    Gauge. 1P2394    Adapter    Plate. 8B7548   Push-Puller     (crossbar     only). 3H465   Platea    (2) S1589   Bolt    5/8-11    NC   44.5    mm    (1.75   in.)    long. 1S379  Washer   (copper). 1D4595   Bolt    5/8-11    NC   152.4    mm    (6.00   in.)    long. 2S736  Washer. The correct cylinder liner projection is important to prevent a leak between the liner, cylinder head, and block. Check cylinder liner projection above the spacer plate as follows: 1. Be sure that the surfaces of the cylinder block, cylinder  liner,  and  the  spacer  plate  are  clean. 2. Install the spacer plate gasket and spacer plate (4) on the cylinder block. Use S1589 Bolts (1) with two 1S379 Washers on each bolt to hold the spacer plate to the cylinder block. Put two bolts with washers on each side of the opening for the cylinder liner. Tighten the bolts evenly, in four steps; 14 N·m (10 lb. ft.), 35 N·m (25 lb. ft.), 70 N·m (50 lb. ft.), and 95 N·m (70 lb. ft.). NOTE: To keep from moving bolts and washers as each liner is checked install two bolts with washers on each side of each cylinder liner, along the complete length  of  the  spacer  plate. 3. Install the cylinder liner without seals in the cylinder block. Put adapter plate (7) on the cy- linder liner as shown. Install crossbar (2) with 1D4595  Bolts  (3),  2S736  Washers,  and  3H465 Plates (5) as shown. Tighten the bolts evenly, in four steps; 7  N-m (5 lb. ft.), 20 Nom (15 lb. ft.), 35 N.m (25 lb. ft.) and 70 N.m (50 lb. ft.). The measurement from the bottom of crossbar (2) to the spacer plate, must be the same on both sides of the cylinder liner. 4-35